Integrated spider separator

ABSTRACT

A vacuum cleaner assembly comprising a body, a motor disposed within the body and having an output shaft for rotating about axis, a fan coupled to the output shaft for generating a vacuum airflow through an air intake port in the body, and a separator coupled to the output shaft. The separator includes a cup shaped body and a flange extending radially from the open top to an outer periphery. The separator includes a spider, integrated therewithin, having a hub portion surrounding the shaft, and a plurality of helical blades integral with and extending radially from the hub portion to the vanes and integral with the wall. The separator is one piece molded component that may provide for better turbulence characteristics during suction of the air, increase the centrifugal forces to separate the dust and debris from the air flow.

[0001] This application claims priority to a provisional patentapplication having a serial number of 60/418,062 filed on Oct. 11, 2002.

1. FIELD OF THE INVENTION

[0002] This invention relates to a vacuum cleaner of the type forhousehold use, and more particularly to a separator with a spidercoupled to an output shaft for generating centrifugal force within theseparator and to prevent liquid from entering into an area between thespider and a blower housing.

2. BACKGROUND OF THE INVENTION

[0003] Vacuum cleaners of various designs are used in residential andcommercial applications for cleaning. These vacuum cleaners create asuction airflow that picks up dirt and dust particulates from a surfaceto be cleaned. The vacuum cleaner separates these particulates from aningested air for later disposal.

[0004] One type of vacuum cleaner design is a canister style vacuumcleaner with a water bath. Water bath vacuum cleaners typically includea main housing with a removably attached water bath pan. The ingestedparticulates are directed into a water bath that absorbs most of theparticulates. The particulates are directed through an inlet in the mainhousing of the vacuum cleaner to an intake opening in the water bathpan.

[0005] The water bath vacuum cleaners typically include a separatorassembly that is used to further separate the particulates from theingested air that escapes entrapment within the water bath.Additionally, the separator can separate the particulates that areentrained within water droplets that are ingested into the separator.The separator provides additional filtration by centrifugation. Toprevent the liquid particulates from entering the area between theseparator and the output shaft of the motor disposed within the housingof the vacuum cleaner, the separator includes a spider. During vacuumcleaning process, the spider rotates with the separator and generates acounter airflow that helps to prevent the water droplets and the dustand dirt particulates from penetrating through the separator andentering inside the motor.

[0006] Numerous designs of a separator having a spider member,incorporated therewithin, are presently known in the art and shown, forexample, in the U.S. Pat. No. 5,090,974 to Kasper et al. and U.S. Pat.No. 5,902,386 to Gustafson et al. featuring the spider removablyattached to a housing of a separator. While prior art patents, citedabove, disclose different designs of the separator including the spiderincorporated therewithin, these prior art designs do not disclose aspider that may reduce a part count. The prior art separators do notprovide for improved balancing during rotation of the separator, and donot provide an effective seal to prevent the liquid particulates fromentering the area between the spider and the blower housing of thevacuum cleaner.

BRIEF SUMMARY OF INVENTION

[0007] The present invention is aimed at one or more of the problemsidentified above. In one aspect of the present invention, a vacuumcleaner assembly comprises a body, a motor disposed within the body andhaving an output shaft for rotating about an axis, a fan coupled to theoutput shaft for generating a vacuum airflow through an air intake portin the body, and a separator coupled to the output shaft for separatingdust and dirt particulates. The separator includes a cup shaped bodyhaving a bottom and a plurality of vanes extending upwardly from thebottom about the bottom axis to an open top. The separator comprises aflange extending radially from the open top to an outer periphery and awall integral with and extending from the flange above the open top. Theinvention includes a spider defined by a hub portion surrounding theshaft and extending upwardly from the bottom to an upper end disposedabove the wall.

[0008] In another aspect of the present invention an integrated spiderseparator for use in a vacuum cleaner assembly that has a body, a motordisposed within the body having an output shaft for rotating about anaxis, a fan coupled to the output shaft for generating a vacuum airflowthrough an air intake port in the housing comprises a separator thatincludes a body having a bottom surrounded by a wall to expose an opentop and coupled to the output shaft for separating dust and dirtparticles. The separator includes a flange integral with the open top ofthe body of the separator and extending radially from the open top to anouter periphery and a spider integral with the flange and extendingupwardly from the bottom to the open top.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Other advantages of the present invention will be readilyappreciated as the same becomes better understood by reference to thefollowing detailed description when considered in connection with theaccompanying drawings wherein:

[0010]FIG. 1 is a perspective view of the vacuum cleaner assembly,partially broken away and in cross section;

[0011]FIG. 2 is a perspective view of the integrated separator withspider;

[0012]FIG. 3 is a side view of the separator of FIG. 2 showing thebeveled bottom edge portions;

[0013]FIG. 4 is an overhead view of the integrated separator of FIG. 2showing the blades and the beveled edges of the vanes;

[0014]FIG. 5 is a cross section along lines 5-5 of FIG. 4;

[0015]FIG. 6 is a cross-section along lines 6-6 of FIG. 3;

[0016]FIG. 7, is an enlarged cross-section of a single vane from FIG. 6;and

[0017]FIG. 8 is an overhead view of an alternative embodiment of theintegrated separator of FIG. 2 showing the blades and the beveled edgesof the vanes.

DETAILED DESCRIPTION OF THE INVENTION

[0018] Referring to the Figures, wherein like numerals indicate like orcorresponding parts throughout the several views a vacuum cleanerassembly is generally shown at 10. The vacuum cleaner assembly 10comprises a body 12 having an intake port 14 and an outlet 16. A motor18 is disposed within the body 12 between the inlet 14 and the outlet 16wherein the motor 18 includes an output shaft 20 for rotating about anaxis. The assembly 10 includes a cooling fan 22, mounted within the body12 above the motor 18 and coupled to the output shaft 20 for generatinga vacuum airflow through the intake port 14 in the body 12 and tocirculate cooling air around the motor 18. The assembly comprises acooling air filter 26 surrounding the motor 18 wherein the cooling airfilter 26 directs the cooling air around the motor 18 and filters thecooling air prior to being exhausted. The assembly 10 includes a blower24 that is mounted within the body 12 below the motor 18. The blower 24provides for drawing air into the intake port 14 and exhausting airoutwardly through the outlet 16.

[0019] The assembly 10 includes a separator, generally shown at 28,coupled to the output shaft 20 to separate dust and dirt particulates.The separator 28 is mounted below the blower 24 and is designed tocirculate the air and a water bath 30 within a water bath pan 32. Acombination of the water bath pan 32 and the water bath 30 is used as aprimary filter for filtering particulates, generally indicated at 34,from the air prior to exhausting the air outwardly through the outlet16.

[0020] As shown in FIGS. 2 and 3, the separator 28 includes a cup shapedbody, generally indicated at 36, having a bottom, generally indicated at38, and a wall, generally indicated at 39, further defined by aplurality of vanes 40 extending upwardly from the bottom 38 about thebottom axis 42 to an open top 44. The vanes 40 comprise a curved flowsurface for increased particulate separation and reductions inaerodynamic losses as the body 36 rotates about the axis 42. The vanes40 extend longitudinally with respect to the body 36 and are generallytapered radially relative to the axis of rotation, i.e., like an airfoil. The curved flow surface extends along the length of each of thevanes 40.

[0021] Referring to FIG. 5, the bottom 38 of the separator 28 comprisesa truncated portion, generally indicated at 46, extending axially from alower bottom 48 toward the open top 44 and then to an upper bottom 50.The upper bottom 50 defines an aperture 52 therein on the axis 42.

[0022] The longitudinally extending vanes 40 define a plurality oflongitudinal gaps or openings 54, formed therebetween. The fluid andparticulates 34 are drawn into the exterior of the separator 28 via thegaps 54. As the particulates 34 are drawn in, separator body 28, whichrotates at a high angular velocity, applies a centrifugal force to theparticulates 34 and the air and water. The particulates 34 are forcedoutwardly against an outer surfaces 56 of the separator body 36 wherethey can be expelled back into the water bath 30 below. The cleaned airis then exhausted from the separator 28 and out through the outlet 16.

[0023] Referring back to FIGS. 2 through 5, the longitudinally extendingvanes 40 include a beveled bottom edge portion 60 that extends outwardlybeyond the bottom portion 38. This beveled bottom edge 60 significantlyreduces foaming that occurs due to the addition of cleaning chemicals orfragrances to the water bath 30. The beveled edge portions 60 on each ofthe vanes 40 reduces a propeller or churning effect created by rotationof the separator 28 and thus reduces foaming. Preferably, the separator28 is formed from a rigid material such as glass filled polystyrenematerial, and the like, and is injection molded.

[0024] The separator 28 includes a flange 62 extending radially from theopen top 44 to an outer periphery 64 and an annular ridge 66 integralwith and extending axially from the flange 62 between the periphery 64and the open top 44. The separator 28 includes a flange wall 70 integralwith and extending from the flange 62 above the open top 44. The wall 70further comprises an annular lip 68 integral with and disposed on theflange wall 70.

[0025] As shown in FIGS. 2 through 5, the separator 28 comprises aspider, generally indicated at 72, being integral with the flange 62.The spider 72 includes a hub portion 74 surrounding the shaft 20 andextending upwardly from the upper bottom 50 to an upper end 76 disposedabove the flange wall 70. The hub portion 74 has a bore 78 aligned withthe aperture 52 wherein the bore 78 is designed to receive a bolt (notshown) when the separator 28 is coupled with the output shaft 20. Thespider 72 includes a plurality of blades 80 integral with and extendingradially and outwardly from the hub portion 74 in a helicalconfiguration to the vanes 40 and integral with the wall 70. As bestshown in FIG. 4, each blade 80 comprises a top 82 and a bottom 84 endswherein each bottom end 84 of the blade 80 defines a groove, generallyindicated at 86, to engage the truncated portion 46 defined by the upper50 and lower 48 bottoms. Although the illustrated embodiment shows theblades 80 integral with and extending radially and outwardly from thehub portion 74 in a helical configuration to the vanes 40, other bladedesigns may be used. For example, in one alternative embodiment, shownin FIG. 8, blades 90 are straight and extend diagonally from the hubportion 74 of the spider 72.

[0026] The spider 72 rotates with the separator 28 and generates acounter airflow that helps to prevent the water droplets (not shown) andthe dirt and dust particulates 30 from penetrating through the separator28 and entering inside the motor 18. In addition, the spider 72 providesa seal that prevents dirt-entrained liquid from entering between thespider 72 and the blower 24. Preferably, the spider 72, the flange 62,and the wall 70 are integrally formed from a rigid material such asglass filled polystyrene material, and the like, and are injectionmolded.

[0027] The invention has been described in an illustrative manner, andit is to be understood that the terminology, which has been used, isintended to be in the nature of words of description rather than oflimitation.

[0028] Obviously, many modifications and variations of the presentinvention are possible in light of the above teachings. It is,therefore, to be understood that within the scope of the appendedclaims, wherein reference numerals are merely for convenience and arenot to be in any way limiting, the invention may be practiced otherwisethan as specifically described.

What is claimed is:
 1. A vacuum cleaner assembly comprising: a body; amotor disposed within said body and having an output shaft for rotatingabout an axis; a fan coupled to said output shaft for generating avacuum airflow through an air intake port in said housing; a separatorhaving a body including a bottom surrounded by a wall to expose an opentop and coupled to said output shaft for separating dust and dirtparticles; a flange integral with said open top of said body andextending radially from said open top to an outer periphery; and aspider integral with said flange and extending upwardly from said bottomto said open top.
 2. An assembly as set forth in claim 1 wherein saidspider includes a hub portion having a bore and a plurality of bladesintegral with and extending radially and outwardly in a helicalconfiguration from said hub portion.
 3. An assembly as set forth inclaim 2 wherein said body of said separator is cup shaped.
 4. Anassembly as set forth in claim 3 wherein said wall of said separator isfurther defined by a plurality of vanes extending upwardly from saidbottom about said bottom axis to said open top.
 5. An assembly as setforth in claim 4 including a plurality of longitudinal gaps definedbetween said vanes.
 6. An assembly as set forth in claim 5 wherein saidbottom is further defined by lower and upper bottoms and a truncatedportion extending axially from said lower bottom toward said open top tosaid upper bottom.
 7. An assembly as set forth in claim 6 wherein saidupper bottom has an aperture therein on said axis.
 8. An assembly as setforth in claim 7 wherein said bore of said hub portion is aligned withsaid aperture.
 9. An assembly as set forth in claim 8 wherein saidhelical blades extend radially from said hub portion to said vanes andare integral with said wall.
 10. An assembly as set forth in claim 9wherein said helical blades engage said truncated portion and said upperand lower bottoms of said body.
 11. An assembly as set forth in claim 10wherein each blade includes top and bottom ends wherein each bottom endof said blade defines a groove to engage said truncated portion.
 12. Anassembly as set forth in claim 11 wherein each blade is straight andextends diagonally from said hub portion of said spider.
 13. An assemblyas set forth in claim 1 including an annular ridge integral with andextending axially from said flange between said periphery and said opentop.
 14. An assembly as set forth in claim 13 including a wall integralwith and extending from said flange above said open top.
 15. An assemblyas set forth in claim 14 including an annular lip integral with anddisposed on said wall.
 16. An assembly as set forth in claim 15 whereinsaid spider, said flange, and said wall are integrally formed from arigid material.
 17. An assembly as set forth in claim 16 wherein saidrigid material is a glass filled polystyrene.
 18. An assembly as setforth in claim 17 wherein said spider, said flange, and said wall areinjection molded.
 19. A vacuum cleaner assembly comprising: a body; amotor disposed within said body and having an output shaft for rotatingabout an axis; a fan coupled to said output shaft for generating avacuum airflow through an air intake port in said housing; a cooling airfilter surrounding said motor wherein said cooling air filter directsthe cooling air around said motor and filters the cooling air prior tobeing exhausted; a blower mounted within said body below said motorproviding for drawing air into said intake port and exhausting airoutwardly through an outlet; a separator coupled to said output shaftfor separating dust and dirt particulates and including a cup shapedbody having a bottom and a plurality of vanes extending upwardly fromsaid bottom about said bottom axis to an open top; said bottom havingtruncated portion extending axially from a lower bottom toward said openend to an upper bottom; said upper bottom having an aperture therein onsaid axis; a flange extending radially from said open top to an outerperiphery; an annular ridge integral with and extending axially fromsaid flange between said periphery and said open top; a wall integralwith and extending from said flange above said open top; an annular lipintegral with and disposed on said wall; a hub portion surrounding saidshaft and extending upwardly from said upper bottom to an upper enddisposed above said wall and having a bore aligned with said aperture; aplurality of blades integral with and extending radially and outwardlyin a helical configuration from said hub portion to said vanes andintegral with said wall, said blades engaging said truncated portion andsaid upper and lower bottoms; and said helical blade including top andbottom ends wherein each bottom end of said blade defining a groove toengage said truncated portion.
 20. An integrated spider separator foruse in a vacuum cleaner assembly having a body, a motor disposed withinsaid body and having an output shaft for rotating about an axis, a fancoupled to said output shaft for generating a vacuum airflow through anair intake port in said housing comprising: a separator having a bodyincluding a bottom surrounded by a wall to expose an open top andcoupled to said output shaft for separating dust and dirt particles; aflange integral with said open top of said body and extending radiallyfrom said open top to an outer periphery; and a spider integral withsaid flange and extending upwardly from said bottom to said open top.21. An integrated spider separator as set forth in claim 20 wherein saidspider includes a hub portion having a bore and a plurality of bladesintegral with and extending radially and outwardly in a helicalconfiguration from said hub portion.
 22. An integrated spider separatoras set forth in claim 21 wherein said body of said separator is cupshaped.
 23. An integrated spider separator as set forth in claim 22wherein said wall of said separator is further defined by a plurality ofvanes extending upwardly from said bottom about said bottom axis to saidopen top.
 24. An integrated spider separator as set forth in claim 23including a plurality of longitudinal gaps defined between said vanes.25. An integrated spider separator as set forth in claim 24 wherein saidbottom is further defined by lower and upper bottoms and a truncatedportion extending axially from said lower bottom toward said open top tosaid upper bottom.
 26. An integrated spider separator as set forth inclaim 25 wherein said upper bottom has an aperture therein on said axis.27. An integrated spider separator as set forth in claim 26 wherein saidbore of said hub portion is aligned with said aperture.
 28. Anintegrated spider separator as set forth in claim 27 wherein saidhelical blades extend radially from said hub portion to said vanes andare integral with said wall.
 29. An integrated spider separator as setforth in claim 28 wherein said helical blades engage said truncatedportion and said upper and lower bottoms of said body.
 30. An integratedspider separator as set forth in claim 29 wherein each blade includestop and bottom ends wherein each bottom end of said blade defines agroove to engage said truncated portion.
 31. An integrated spiderseparator as set forth in claim 30 wherein each blade is straight andextends diagonally from said hub portion of said spider.
 32. Anintegrated spider separator as set forth in claim 20 including anannular ridge integral with and extending axially from said flangebetween said periphery and said open top.
 33. An integrated spiderseparator as set forth in claim 32 including a wall integral with andextending from said flange above said open top.
 34. An integrated spiderseparator as set forth in claim 33 including an annular lip integralwith and disposed on said wall.
 35. An integrated spider separator asset forth in claim 34 wherein said spider, said flange, and said wallare integrally formed from a rigid material.
 36. An integrated spiderseparator as set forth in claim 35 wherein said rigid material is aglass filled polystyrene.
 37. An integrated spider separator as setforth in claim 36 wherein said spider, said flange, and said wall areinjection molded.